Rectangular stranded conductor and method of manufacturing the same

Abstract

The application relates to the technical field of data connection lines, and discloses a rectangular stranded conductor conducting cable and a manufacturing method thereof, which comprises a wire body and an insulating layer wrapped on the outer layer of the wire body, the wire body comprises a core wire and a core sheath, the cross section of the core wire is in a rectangular shape, and the core sheath is wrapped on the outer side of the core wire; the cross section of the core wire is set as a rectangular shape, so that the occupying area of the core wire is better improved; under the premise of the same specification of the data line, the proportion of the core wire is higher, the same current rating can be borne, the data line can be made longer, long-distance data transmission is realized, and the current bearing capacity can be improved under the condition that the length of the data line is the same.

Description

Technical Field

[0001] This invention relates to the field of data connection technology, and in particular to a conductive cable with a rectangular stranded conductor and its manufacturing method. Background Technology

[0002] Conductive cables, also known as data cables, typically consist of several power and signal wires combined to form a cable body, which is then wrapped with an insulation layer. The core wires of the power wires are made of multi-strand copper wires twisted together. In existing technology, the core wires of power cables mostly adopt a circular cross-section design, with the core wires being multi-strand copper wires twisted together. Given a fixed width and thickness of the entire cable body, the spatial position and range occupied by the core wires within the cross-section are strictly constrained by industry standards. After all the core wires are arranged, the outer insulation layer wraps around the entire cable. At this point, a certain gap thickness must be maintained between the outer wall of the core wire and the inner wall of the insulation layer. This gap must be maintained within the range required by design specifications. A gap that is too thin will significantly reduce the lifespan of the power cable, especially in retractable cable structures. Due to frequent bending and stretching, a thin insulation layer is more prone to premature damage, aging, and cracking, thus posing electrical safety risks.

[0003] Under the same external dimensions and current carrying capacity requirements, maximizing the effective cross-sectional area (i.e., copper wire capacity) of the core wire while ensuring the safe thickness of the insulation layer has become a key technical bottleneck for extending the maximum effective transmission length of power cables. Traditional data cables generally use round core wires. Under these constraints, the space utilization of round core wires is relatively limited. If it is necessary to increase the copper wire capacity, multiple sets of core wires can be added for expansion. However, in order to prevent friction and bulging between adjacent core wires, gaps inevitably exist, which cannot fully occupy the usable space inside the cable body and limit further improvement of cable performance. Therefore, improvements are needed. Summary of the Invention

[0004] The main objective of this invention is to propose a conductive cable with a rectangular stranded conductor, which aims to provide a data cable that maximizes the effective cross-sectional area of ​​the conductor inside the positive and negative power lines.

[0005] To achieve the above objectives, the present invention proposes a conductive cable with a rectangular stranded conductor, comprising a wire body and an insulating layer covering the outer layer of the wire body. The wire body includes a core wire and a core sheath, the core wire having a rectangular cross-section, and the core sheath covering the outer side of the core wire.

[0006] Specifically, the wire body includes one or more of the following: power line, ground line, signal line, Vconn line, CC line, or electronic line.

[0007] Specifically, the insulating layer contains an insulating filler, the core skin is in close contact with the insulating filler to form an insulating spacer layer, and there is a transverse insulating spacer layer and a vertical insulating spacer layer between the outer wall of the core skin and the inner wall of the insulating layer. The thickness of the transverse insulating spacer layer is greater than or equal to 0.25 mm, and the thickness of the vertical insulating spacer layer is greater than or equal to 0.10 mm.

[0008] Specifically, the core wire comprises several stranded conductors, and the concentricity between the sheath and the core wire is greater than 80%.

[0009] Specifically, the surface of the insulating layer is provided with a plurality of anti-slip grooves, each protective groove is spaced apart from the others, the spacing between each protective groove is the same, and each protective groove is coaxially arranged along the extension direction of the positive power line, the negative power line, or the signal line.

[0010] Specifically, the core sheath is made of foamed insulating material, non-foamed insulating material, or insulating composite material, wherein the insulating composite material is formed by mixing foamed insulating material and non-foamed insulating material.

[0011] Specifically, the insulating layer is made of non-foamed insulating material or composite insulating material.

[0012] To achieve the above objectives, the present invention also provides a method for manufacturing conductive cables, comprising the following manufacturing steps: S1. Twisting several wires together to form a core wire; S2. Cover the outer surface of the core wire with a core sheath; S3. Place the core wire covered with the core sheath into a rectangular shaping fixture, and roll it with shaping rollers to form a rectangular stranded conductor. S4. A wire is formed by covering the rectangular stranded conductor with an insulating layer.

[0013] Specifically, the shaping roller includes a shaping cold roller and / or a shaping hot roller.

[0014] The technical solution of this invention sets the cross-section of the core wire to a rectangular shape, so as to better improve the core wire's area occupied. Under the premise of the same data cable specification, the core wire has a higher proportion. When carrying the same current rating, the data cable can be made longer, realizing data transmission over a longer distance. Under the premise of the same data cable length, the current carrying capacity can be improved. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0016] Figure 2 for Figure 1 An enlarged schematic diagram of point A.

[0017] Figure 3 This is a cross-sectional view of the present invention.

[0018] The reference numerals in the attached diagram include: 10, wire body; 11, positive power supply wire; 12, negative power supply wire; 13, signal wire; 14, anti-slip groove; 15, core wire; 16, core sheath; 20, insulation layer; 21, horizontal insulation spacer layer; 22, vertical insulation spacer layer. Detailed Implementation

[0019] The technical solutions in the embodiments of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, top, bottom, inside, outside, vertical, horizontal, longitudinal, counterclockwise, clockwise, circumferential, radial, axial, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0021] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0022] like Figures 1 to 3As shown, a conductive cable with a rectangular stranded conductor includes a wire body 10 and an insulation layer 20 covering the outer layer of the wire body 10. The wire body 10 includes a core wire 15 and a core sheath 16. The cross-section of the core wire 15 is rectangular, and the core sheath 16 covers the outer side of the core wire 15. The core wire 15 is rectangular in cross-section to improve its usability. Compared to existing technologies that use multiple circular cross-section wires, this method significantly increases the capacity of the core wire 15 within the wire body. The circular cross-section wires have gaps between them to prevent friction and bulging of the core sheaths 16 between different wires 10 during use, which would reduce the lifespan of the data cable. These gaps occupy limited space; therefore, in situations with specific and limited space, the utilization rate of a rectangular cross-section core wire 15 is much higher than that of multiple circular cross-section core wires 15 arranged together. This increases the proportion of core wires 15 in the data cable, allowing the data cable to be made longer while carrying the same rated current, enabling longer-distance data transmission. It also increases the current carrying capacity for the same data cable length. Similarly, instead of a circular cross-section core wire 15, an elliptical cross-section core wire 15 can also be used, further increasing the proportion of copper wires within the core wire 15.

[0023] The wire body 10 includes one or more of the following: power line, ground line, signal line, Vconn line, CC line, or electronic line. In this embodiment, the wire body 10 includes a positive power line 11, a negative power line 12, and a signal line 13, as shown in the attached figure. Figure 2 As shown, in this embodiment, only the core wires 15 of the positive power line 11 and the negative power line 12 have rectangular cross-sections, while the core wire 15 of the signal line 13 still has a circular cross-section. This improves the current carrying capacity of the positive power line 11 and the negative power line 12. Similarly, the core wire 15 of the signal line 13 can also be rectangular to improve the data transmission capacity of the signal line 13. In addition, in this embodiment, the insulation layer 14 is rectangular after wrapping the wire body 10, but it can also be made circular after wrapping the wire body 10 by injection molding. In addition, in specific implementations, grounding wires, electronic wires, Vconn wires, CC wires, etc., can also be added. In this embodiment, the Vconn wire is a dedicated power supply wire for supplying power to the inner core of the cable. The CC wire refers to the Configuration Channel, which is a key channel for communication and negotiation between devices in the USB Type-C interface. It consists of two pins, CC1 and CC2. The relevant configurations can be assembled and adjusted according to actual usage requirements, which will not be elaborated here.

[0024] An insulating filler is provided within the insulating layer 20. The core 16 is in close contact with the insulating filler to form an insulating spacer layer. A transverse insulating spacer layer 21 and a vertical insulating spacer layer 22 are provided between the outer wall of the core 16 and the inner wall of the insulating layer 20. The thickness of the transverse insulating spacer layer 21 is greater than or equal to 0.25 mm, and the thickness of the vertical insulating spacer layer 22 is greater than or equal to 0.10 mm. In this embodiment, the thickness of the transverse insulating spacer layer 21 is greater than or equal to 0.25 mm, and the thickness of the vertical insulating spacer layer 22 is greater than or equal to 0.10 mm to meet industry standard requirements. This also ensures the minimum thickness of the transverse insulating spacer layer 21 and the vertical insulating spacer layer 22, preventing the data cable from being easily worn due to excessive thickness. Especially during extended use, the friction between the insulating layer 20 and the outside increases. If the thickness is too thin, the inner core wire 15 will be easily exposed, leading to a reduction in the lifespan of the data cable. The insulating filler can be one or more of the following tensile materials: copper foil wire, copper alloy, nylon wire, Kevlar, etc. The tensile strength of the cable is increased by adding the insulating filler. The diameter range of the insulating filler is preferably 40um-1000um.

[0025] The core wire 15 comprises several twisted conductors, and the concentricity between the core sheath 16 and the core wire 15 is greater than 80%. During signal transmission in the data line, an electric field is formed between the data line and the reference plane at a point where the signal arrives. Due to the presence of the electric field, a small instantaneous current is generated, which exists at every point in the data line. Simultaneously, the signal also has a certain voltage. Thus, during signal transmission, each point of the data line is equivalent to a resistor, which is the characteristic impedance of the data line. In this embodiment, the concentricity between the core sheath 16 and the core wire 15 is greater than 80%, which helps to reduce the dielectric constant of the insulation layer 20 of the core wire 15, reduce external interference, and facilitate the adjustment of the characteristic impedance to the standard range. Furthermore, the core sheath 16 is not limited to a solid layer, a semi-hollow tube layer, or a foamed layer.

[0026] The surface of the insulation layer 20 is provided with a plurality of anti-slip grooves 14, which are spaced apart from each other and are equidistant from each other. All the anti-slip grooves are coaxially arranged along the extension direction of the cable 10. In this embodiment, the anti-slip grooves 14 on the surface of the insulation layer 20 facilitate better gripping of the data cable, thereby improving the user experience. Furthermore, the anti-slip grooves 14 can also be arranged horizontally or at an angle to accommodate the different needs of more products; alternatively, the surface of the insulation layer 20 can be made smooth, and an anti-slip effect can be achieved by directly applying a silicone sleeve to the outside of the insulation layer 20, thereby improving the product's texture.

[0027] The core sheath 16 is made of foamed insulating material, non-foamed insulating material, or insulating composite material, wherein the insulating composite material is formed by mixing foamed insulating material and non-foamed insulating material. In one embodiment, the core sheath 16 can be made of foamed insulating materials such as foamed PE, foamed PP, and foamed TFLON; in another embodiment, the core sheath 16 can be made of non-foamed insulating materials such as PP, PE, PVC, TPE, TPU, TFLON, FEP, and TPEE; in a third embodiment, the core sheath 16 can be made of insulating composite materials such as foamed PE and PE composites, foamed PE and PP composites, foamed PE and TFLON composites, foamed PP and PE composites, foamed PP and PP composites, foamed PP and TFLON composites, foamed TFLON and PE composites, foamed TFLON and PP composites, and foamed TFLON and TELON composites.

[0028] When the core skin 16 is made of composite materials, a double-layer co-extrusion structure is adopted to form the core skin 16. The mass ratio of foamed insulation material to non-foamed insulation material is 5:5 to 8:2, wherein the mixing ratio of foamed PE mixed with PE and foamed PE mixed with PP is 6:4 to 7:3; wherein the mixing ratio of foamed PP mixed with PE and foamed PP mixed with PP is 6:4 to 7:3; wherein the mixing ratio of foamed PP mixed with PTFE, foamed PE mixed with PTFE, foamed PTFE mixed with PE and foamed PTFE mixed with PP is 7:3 to 8:2; and wherein the mixing ratio of foamed PTFE mixed with PTFE is 5:5 to 6:4.

[0029] The relationship between the mass fraction of composite materials and their dielectric constant is shown in the table below:

[0030] The insulating layer 20 is made of non-foamed insulating material or composite insulating material. In one embodiment, the insulating layer 20 can be made of non-foamed insulating materials such as silicone, PVC, TPE, TPU, FEP, and rubber; in another embodiment, the insulating layer 20 can be made of composite insulating materials such as composite materials of TPU and TPE, composite materials of TPU and magnetic materials, composite materials of TPE and magnetic materials, and composite materials of silicone and magnetic materials.

[0031] The present invention also proposes a method for manufacturing conductive cables, comprising the following manufacturing steps: S1, stranding several copper wires to form a core wire 15; S2, covering the outer surface of the core wire 15 with a core sheath 16; S3, placing the core wire 15 covered with the core sheath 16 into a rectangular shaping fixture, and rolling and shaping it by means of a shaping roller to form a rectangular stranded conductor; S4, covering the rectangular stranded conductor with an insulation layer 20 to form a wire body 10. In this embodiment, the material of the core wire 15 can be tin-plated copper, bare copper, alloy copper, enameled copper, etc. Those skilled in the art can choose according to actual needs. When making the data cable, multiple copper wires are first twisted together to form the core wire 15. Then, a core sheath 16 is wrapped around the core wire 15 to form the positive power line 11 or the negative power line 12. The core wire 15 covered with the core sheath 16 is then placed in a rectangular shaping fixture. The core wire 15 is rolled by a pressure roller. The rolling method can be cold pressing, hot pressing, or a combination of cold and hot pressing, so that the core wire 15 changes from a circle to a rectangle. Then, it is combined with the signal line 13 and wrapped with an insulation layer 20 to form a data cable. The positive power wire 11 or negative power wire 12 of this data cable, with the same cross-sectional area, minimizes the volume occupied by the core wire 15 and reduces the overall thickness of the core wire 15. This helps ensure the minimum thickness of the horizontal insulation spacer layer 21 and the vertical insulation spacer layer 22 of the finished data cable, improving the service life of the data cable. At the same time, it can also reduce processing steps, effectively avoid problems such as friction and bulging caused by multiple core wires 15, and improve product yield.

[0032] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A conductive cable with a rectangular stranded conductor, comprising a conductor body and an insulating layer covering the outer layer of the conductor body, characterized in that: The wire consists of a core wire and a sheath. The core wire has a rectangular cross-section, and the sheath covers the outside of the core wire.

2. The conductive cable with a rectangular stranded conductor according to claim 1, characterized in that: The wire body includes one or more of the following: power line, ground line, signal line, Vconn line, CC line, or electronic line.

3. The conductive cable with a rectangular stranded conductor according to claim 1, characterized in that: The insulating layer contains an insulating filler, and the core skin is in close contact with the insulating filler to form an insulating spacer layer. There is a transverse insulating spacer layer and a vertical insulating spacer layer between the outer wall of the core skin and the inner wall of the insulating layer. The thickness of the transverse insulating spacer layer is greater than or equal to 0.25 mm, and the thickness of the vertical insulating spacer layer is greater than or equal to 0.10 mm.

4. The conductive cable with a rectangular stranded conductor according to claim 1, characterized in that: The core wire comprises several stranded conductors, and the concentricity between the sheath and the core wire is greater than 80%.

5. The conductive cable with a rectangular stranded conductor according to claim 1, characterized in that: The surface of the insulating layer is provided with a plurality of anti-slip grooves, each protective groove being spaced apart from the others, with the same spacing between each protective groove, and each protective groove being coaxially arranged along the extension direction of the power positive line, the power negative line, or the signal line.

6. The conductive cable with a rectangular stranded conductor according to claim 1, characterized in that: The core is made of foamed insulation material, non-foamed insulation material or insulating composite material, wherein the insulating composite material is formed by mixing foamed insulation material and non-foamed insulation material.

7. The conductive cable with a rectangular stranded conductor according to claim 1, characterized in that: The insulating layer is made of non-foamed insulating material or composite insulating material.

8. A method for manufacturing the conductive cable according to any one of claims 1 to 7, characterized in that, The manufacturing process includes the following steps: S1. Twisting several wires together to form a core wire; S2. Cover the outer surface of the core wire with a core sheath; S3. Place the core wire covered with the core sheath into a rectangular shaping fixture, and roll it with shaping rollers to form a rectangular stranded conductor. S4. A wire is formed by covering the rectangular stranded conductor with an insulating layer.

9. A method for manufacturing a conductive cable according to claim 8, characterized in that, The shaping rollers include shaping cold rollers and / or shaping hot rollers.

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